Automated Component Supply Unit Loading Using Conveyance Robots
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Solution Overview
Problem
The loading operation of component supply units with component containers requires significant manual labor and complicates management, as operations before and after the loading are not fully automated.
Innovation Solution
A system that automates the loading of component supply units using container and unit conveyance robots, along with a control system to manage and coordinate the conveyance and loading operations, enabling full automation of the loading process and related transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual loading operation is used, then labor cost is high, but automation extent is low
Solution Approach 1:
The system is divided into distinct functional modules: container warehouse for storage, container conveyance robot for transportation, container loader for loading operations, and unit storage shed for finished goods storage. This segmentation allows each module to be optimized independently while maintaining overall system automation.
Solution Approach 2:
The container loader acts as an intermediary device between the container conveyance robot and the unit storage shed. It receives containers from the conveyance robot, performs the loading operation onto component supply units, and transfers the loaded units to storage, thereby automating the previously manual loading process.
2Productivity
If loading operation is automated, then labor saving is achieved, but device complexity increases
Solution Approach 1:
The container conveyance robot and unit conveyance robot serve multiple functions: they transport containers to the loader, transport loaded units to storage, and can potentially serve multiple loading stations. This multi-functionality improves productivity while limiting the increase in device complexity.
Solution Approach 2:
The system employs automated conveyance robots that operate autonomously to transport containers and loaded units. The container loader automatically performs the loading operation without manual intervention, allowing the system to serve itself and eliminating the need for manual labor in these operations.
3Productivity
If work-in-process component supply units are increased to meet production plans, then production scheduling is ensured, but management complexity increases
Solution Approach 1:
The automated loading system performs loading operations in advance based on production plans, allowing component supply units to be prepared and staged in the unit storage shed before they are needed on the production line. This preliminary action ensures production schedules are met while reducing the need for complex real-time management of work-in-process inventory.
Data Source
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AI summary
A component supply unit set-up system includes a container warehouse configured to store multiple component containers for containing multiple components, a unit storage shed configured to store multiple component supply units used when the component, which is contained in the component container, is supplied in a mounting operation performed by a component mounter, a work table disposed between the container warehouse and the unit storage shed and used for a loading operation of loading the component supply unit with the component container , a container conveyance robot configured to convey the component container between the container warehouse and the work table, and a unit conveyance robot configured to convey the component supply unit between the unit storage shed and the work table.